The other day I was using FastCap's Kaizen Foam to create a new box for storing my molding head cutter set. I had several scraps left over and it occured to me that these could be pretty easily shaped into custom sanding blocks profiled moldings. I tested the concept and it worked out quite nicely.

Then, because this is how my mind works, I wondered if I could get similar results with other kinds of foam. A lot of electronics get shipped packed inside foam padding, so I rummaged through some of the old laptop boxes I had in my attic. On the left is a scrap of the Kaizen Foam, the center and right are packing from various electronics.

I cut a block from the packing that was the right size to comfortably hold, and traced the molding profile onto one end. I then carved the bottom of the block to fit the tracing. I found that a 'snap blade' knife is excellent for this since you can extend or retract the blade as needed for making deep or shallow cuts. It only took a few minutes to create a sanding block that fit my profile very nicely.

PSA sandpaper can be stuck directly on the block, or plain sheets can be attached with spray adhesive. (you do not want to use solvent based adhesives like contact cement since it will probably melt the foam) You want to use a sanding sheet with a thin backer so that it conforms well to the profile of the block. Rolling the sheet tightly then unrolling it can 'break down' the backer somewhat so that it conforms better.

In previous editions of this blog I have looked at other ways to create profile sanding blocks. I've tried the deck of cards trick as well as using automotive filler, but foam is quick, easy and cheap. Try it out, I think you will want to remember this the next time you have a profile to sand.

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